Surgical forceps having jaw members

ABSTRACT

An electrosurgical instrument includes a housing and an elongated shaft extending from the housing. An end effector is disposed at a distal portion of the elongated shaft. The end effector is configured to deliver electrosurgical energy to tissue. The end effector includes a first jaw member having a first electrode plate and a second jaw member having a second electrode plate. A movable handle is operably coupled to the housing. The movable handle is configured to move at least one of the first or second jaw members between an open position and a closed position. A first plate is disposed on the first jaw member. A second plate is disposed on the first plate. The second plate includes an opening defined therein. A bead is disposed on the first plate and is configured to protrude through the opening defined in the second plate.

BACKGROUND Technical Field

The present disclosure relates to surgical instruments and methods and,more particularly, to surgical forceps having jaw members configured toseal tissue.

Background of Related Art

Open or endoscopic electrosurgical forceps utilize both mechanicalclamping action and electrical energy to effect hemostasis. Theelectrode of each opposing jaw member is charged to a different electricpotential such that when the jaw members grasp tissue, electrical energycan be selectively transferred through the tissue. A surgeon can treattissue by either cauterizing, coagulating/desiccating, sealing, and/orsimply reducing or slowing bleeding, by controlling the intensity,frequency and duration of the electrosurgical energy applied between theelectrodes and through the tissue.

In order to promote accurate, consistent and effective, sealing andother tissue treatment effects, one or more insulative stop members maybe positioned along one or both opposed surfaces of the jaw members tomaintain a specific gap distance between the jaw members when the jawmembers are in a clamping position with tissue grasped therebetween.

The stop members may be secured to the opposed surfaces of the jawmembers via one or more suitable securement methods. The currenttechniques of forming and securing the stop members to the opposedsurfaces of the jaw members may require specialty equipment, precisetolerances, and/or introduce process variability which increases themanufacturing cost of the jaw members.

SUMMARY

An electrosurgical instrument provided in accordance with aspects of thepresent disclosure includes a housing and an elongated shaft extendingfrom the housing. An end effector is disposed at a distal portion of theelongated shaft. The end effector is configured to deliverelectrosurgical energy to tissue. The end effector includes a first jawmember having a first electrode plate and a second jaw member having asecond electrode plate. A movable handle is operably coupled to thehousing. The movable handle is configured to move at least one of thefirst or second jaw members between an open position and a closedposition. A first plate is disposed on the first jaw member. A secondplate is disposed on the first plate. The second plate includes anopening defined therein. A bead is disposed on the first plate and isconfigured to protrude through the opening defined in the second plate.

In aspects according to the present disclosure, the first plate includesan indent defined therein configured to support the bead.

In aspects according to the present disclosure, the first plate includesan opening defined therein that supports a bottom surface of the beadatop the first jaw member.

In aspects according to the present disclosure, the first plate and thesecond plate form a substantially spherical shape around the bead.

In aspects according to the present disclosure, the bead includes alower portion having a first width and an upper portion have a secondwidth smaller than the first width. The upper portion of the bead havingthe second width projects through the opening defined in the secondplate.

In aspects according to the present disclosure, the end effectorincludes a knife configured to cut tissue disposed between the first andsecond jaw members.

In aspects according to the present disclosure, an activation buttonextends from the housing and in registration with the movable handle.Selective actuation of the movable handle controls the delivery ofelectrosurgical energy to the first and second jaw members.

In aspects according to the present disclosure, the bead has asubstantially spherical shape.

In aspects according to the present disclosure, the first plate and thesecond plate are mechanically welded together.

An electrosurgical instrument provided in accordance with aspects of thepresent disclosure includes an electrosurgical instrument including ahousing and an elongated shaft extending from the housing. An endeffector is disposed at a distal portion of the elongated shaft. The endeffector is configured to deliver electrosurgical energy to tissue. Theend effector includes a first jaw member and a second jaw member. Atleast the first jaw member includes a jaw support including a pluralityof capture tabs disposed thereon. A movable handle is operably coupledto the housing and is configured to move at least one of the first orsecond jaw members between an open position and a closed position. Aseries of spacers are disposed on the jaw support and are seated betweenthe capture tabs. A sealing plate includes a corresponding series ofopenings defined therethrough configured to capture each respectivespacer such that each spacer protrudes therethrough. An insulativehousing is configured to secure the sealing plate atop the jaw support.

A method of manufacturing an electrosurgical instrument in accordancewith aspects of the present disclosure includes positioning a firstplate including a plurality of indents on a first jaw member of an endeffector assembly. The method includes positioning at least one bead inan indent of the plurality of indents. The method includes positioning asecond plate on the first plate and on the at least one bead. The secondplate includes at least one opening defined therein. The at least oneopening is configured to expose a surface of the bead facing away fromthe first plate. The method includes attaching the first plate to thesecond plate to capture the at least one bead between the first plateand the second plate.

In aspects according to the present disclosure, a first base plate ispositioned on the first jaw member. A second base plate is positioned onthe first base plate. The second base plate forms a laterally facingattachment notch with the first base plate. An overmold layer is formedabout the first jaw member. The overmold layer is formed in thelaterally facing attachment notch to secure the first and second baseplates to the first jaw member.

In aspects according to the present disclosure, the spacer is coupled tothe first jaw member.

In aspects according to the present disclosure, the first base plateincludes an opening aligned with an opening of the second base plate. Inother aspects according to the present disclosure, the overmold layerextends through the openings of the first and second base plates.

In aspects according to the present disclosure, a method ofmanufacturing an electrosurgical instrument includes: positioning afirst base plate including a plurality of indents on a first jaw memberof an end effector assembly; positioning one or more spacers in anindent of the plurality of indents; positioning a second base platehaving one or more openings defined therein on the first base plate andon the one or more spacers, the one or more openings exposing a surfaceof the spacer facing away from the first base plate, the second baseplate forming a laterally facing attachment notch with the first baseplate; forming an overmold layer about the first jaw member in thelaterally facing attachment notch to secure the first and second baseplates to the first jaw member.

In aspects according to the present disclosure, a first overmold layeris formed about the first jaw member. In other aspects according to thepresent disclosure, the first overmold layer penetrates the firstopening and the second opening to vertically secure the first and secondbase plates to the first jaw member. In still other aspects according tothe present disclosure, the method includes forming a second overmoldlayer about the first overmold layer, the second overmold layer formedin the laterally facing attachment notch to laterally secure the firstand second base plates to the first jaw member.

In aspects according to the present disclosure, the method includesforming the first overmold layer about the first jaw member, the firstovermold layer forming a first tip protrusion at a distal portion of afirst jaw member and the spacer and the first tip protrusion maintaininga substantially continuous distance between the first and second jawmembers in the closed position.

In aspects according to the present disclosure, the method includesforming a second overmold layer about the second jaw member, the secondovermold layer forming a second tip protrusion at a distal portion ofthe second jaw member, the second tip protrusion directly contacting thefirst tip protrusion when the first and second jaw members are in theclosed position.

In aspects according to the present disclosure, the first and secondbase plates form an overhang extending distally from the first jawmember and the first overmold layer is formed about the overhang formedby the first and second base plates.

In aspects according to the present disclosure, the spacer and the firsttip protrusion maintain a substantially continuous distance between thefirst and second jaw members in the closed position.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the presentdisclosure and, together with the detailed description below, serve tofurther explain the present disclosure, in which:

FIG. 1 is a perspective view of an electrosurgical instrument accordingto the present disclosure with jaw members of the end effector assemblydisposed in an open position;

FIG. 2A is an enlarged perspective view of the electrosurgicalinstrument of FIG. 1 with jaw members of the end effector in an openposition;

FIG. 2B is an enlarged perspective view of the electrosurgicalinstrument of FIG. 1 with jaw members of the end effector in a closedposition;

FIG. 3A is an enlarged perspective view of a spacer and one jaw memberof an end effector according to the present disclosure showing a firstplate disposed atop a support base of the jaw member;

FIG. 3B is an enlarged perspective view of the jaw member of FIG. 3Awith a second plate disposed atop the first plate;

FIG. 3C is an enlarged perspective view of the jaw member of FIG. 3Awith the second plate disposed atop the first plate secured by an outerinsulative overmold;

FIG. 4A is an enlarged side view of the spacer disposed through both thefirst plate and through the second plate;

FIG. 4B is a greatly enlarged cross-sectional view of the spacer takenalong lines 4B-4B of FIG. 4A;

FIG. 5A is an enlarged perspective view of a plurality of spacersaccording to another embodiment of the present disclosure;

FIG. 5B is an enlarged cross-sectional view of the jaw member of FIG. 5Awith a seal plate disposed thereon;

FIG. 6A is an enlarged, perspective view of a jaw member havingplurality of capture tabs according to an embodiment of the presentdisclosure;

FIG. 6B is an enlarged, cross-sectional view of the jaw member of FIG.6A illustrating a two-plate construction secured by an overmold layer;

FIG. 6C is an enlarged, cross-sectional view of the jaw member of FIG.6A illustrating a two-plate construction secured by an overmold layervertically extending through openings formed in first and second baseplates;

FIG. 7A is an enlarged, side view of an electrosurgical instrumentincluding mold-through dots according to the present disclosure with jawmembers of the end effector assembly disposed in a closed positionhaving tip protrusions; and

FIG. 7B is an enlarged perspective view of a jaw member of the endeffector assembly of FIG. 7A having a tip protrusion.

DETAILED DESCRIPTION

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.Further, to the extent consistent, any of the aspects and featuresdetailed herein may be used in conjunction with any or all of the otheraspects and features detailed herein.

As used herein, the terms parallel and perpendicular are understood toinclude relative configurations that are substantially parallel andsubstantially perpendicular up to about + or −10 degrees from trueparallel and true perpendicular.

“About” or “approximately” as used herein may be inclusive of the statedvalue and means within an acceptable range of variation for theparticular value as determined by one of ordinary skill in the art,considering the measurement in question and the error associated withmeasurement of the particular quantity (e.g., the limitations of themeasurement system). For example, “about” may mean within one or morestandard variations, or within ±30%, 20%, 10%, 5% of the stated value.

Descriptions of technical features or aspects of an exemplary embodimentof the present disclosure should typically be considered as availableand applicable to other similar features or aspects in another exemplaryembodiment of the present disclosure. Accordingly, technical featuresdescribed herein according to one exemplary embodiment of the presentdisclosure may be applicable to other exemplary embodiments of thepresent disclosure, and thus duplicative descriptions may be omittedherein.

Exemplary embodiments of the present disclosure will be described morefully below (e.g., with reference to the accompanying drawings). Likereference numerals may refer to like elements throughout thespecification and drawings.

Referring generally to FIGS. 1, 2A and 2B, a surgical instrumentprovided in accordance with the present disclosure is shown generallyidentified by reference numeral 10. Instrument 10, as described below,is configured for grasping, treating, and/or dissecting tissue and mayfind particular applicability for use in performing tonsillectomy and/oradenoidectomy procedures, although use of instrument 10 in various othersurgical procedures is also contemplated and within the scope of thepresent disclosure.

Instrument 10 generally includes a housing 20, a handle assembly 30, atrigger assembly 70, a shaft 80, an end effector assembly 100, a driveassembly 140, a knife assembly 170, and an energy activation assembly190. Shaft 80 extends distally from housing 20 (e.g., along a plane2-2—see, e.g., FIG. 1 ) and supports end effector assembly 100 at distalend 82 thereof. Drive assembly 140 operably couples handle assembly 30with end effector assembly 100 to enable selective manipulation of jawmembers 110, 120 of end effector assembly 100. Knife assembly 170 isoperably coupled with trigger assembly 70 to enable selectivetranslation of a knife blade 174 of knife assembly 170 relative to endeffector assembly 100. Energy activation assembly 190 enables energy tobe selectively delivered to end effector assembly 100.

Instrument 10 may also include an electrosurgical cable (not shown) thatconnects instrument 10 to a generator (not shown) or other suitablepower source, although instrument 10 may alternatively be configured asa battery-powered instrument. The electrosurgical cable includes leadwires, e.g., lead wires 107, extending therethrough that have sufficientlength to extend through housing 20 and shaft 80 in order to operablycouple the generator, energy activation assembly 190, and end effectorassembly 100 with one another to enable the selective supply of energyto electrically-conductive plates 112, 122 of jaw members 110, 120 ofend effector assembly 100, e.g., upon activation of energy activationassembly 190.

For a more detailed description of instrument 10, reference may be madeto U.S. Pat. No. 9,918,779, entitled “SURGICAL INSTRUMENTS AND METHODSFOR PERFORMING TONSILLECTOMY, ADENOIDECTOMY, AND OTHER SURGICALPROCEDURES,” the entire contents of which are incorporated by referenceherein. However, the aspects and features of the present disclosure areequally applicable for use with other suitable surgical instruments.

Although only the features of jaw member 110 or jaw member 120 aredescribed below and/or illustrated in the figures, it is noted that jawmembers 110, 120 defines mirror-image configurations of one another(unless specifically contradicted herein) and, thus, any descriptionand/or illustration of one jaw member 110, 120 applies similarly to theother jaw member 110, 120.

Referring to FIGS. 1, 2A, 2B, 3A, 3B and 3C, electrosurgical instrumentprovided in accordance with aspects of the present disclosure includeshousing 20 and elongated shaft 80 extending from the housing 20. The endeffector 100 is disposed at a distal portion of the elongated shaft 80.The end effector 100 is configured to deliver electrosurgical energy totissue. The end effector 100 includes first jaw member 110 having afirst electrode plate 112 and second jaw member 120 having a secondelectrode plate 122. Movable handle 30 is operably coupled to thehousing 20. The movable handle 30 is configured to move at least one ofthe first or second jaw members 110 or 120 between an open position(see, e.g., FIG. 2A) and a closed position (see, e.g., FIG. 2B).

The end effector 100 includes the knife 170 configured to cut tissuedisposed between the jaw members 110 and 120. The activation button 190extends from the housing 20 and is in registration with the movablehandle 30. Selective actuation of the movable handle 30 controls thedelivery of electrosurgical energy to the jaw members 110 and 120.Actuation of the moveable handle 30 also controls opening and closing ofthe end effector 100.

A spacer 300 is positioned on jaw member 110 (although it is envisionedthat the spacer 300 may be disposed on jaw member 120). The spacer 300may be ball-like or cylindrical in nature and may be made from aceramic, glass, metal or the like. As an example, the spacer 300 may beconical in shape. As explained in more detail below, the spacer 300 isconfigured to operably engage a first plate 301 disposed on a supportbase 116 of jaw member 110. First plate 301 and support base 116 may beseparate components or may be integral with one another.

A second plate 302 is disposed on or atop the first plate 301 invertical registry therewith. Second plate 302 may include one or moremechanical features (not shown) that facilitate alignment atop firstplate 301 or that facilitate secure engagement with first plate 301. Thesecond plate 302 includes one or more openings 303 defined therein. Oneor more beads 304 is disposed atop (or is otherwise engaged with) thefirst plate 301 and each bead is configured to protrude through arespective opening 303 defined in the second plate 302. The bead(s) maybe made from metal, glass, ceramic, plastic, minerals, or another typeof material depending upon a particular purpose. The description of thefirst and second plates 301 and 302 with respect to the first jaw member110 is similarly applicable to the second jaw member 120. Thus, eitheror both of the first and second jaw members 110 and/or 120 may include atwo plate construction technique as described herein.

In a configuration in which each of the first and second jaw members 110and 120 include beads (e.g., beads 304) as described herein, a beadpositioned on the first jaw member 110 may directly contact acorresponding bead positioned on the second jaw member 120.

The beads 304 are captured between the first plate 301 and the secondplate 302, while protruding through an upper surface of the second plate302 to oppose jaw member 120. When the end effector 100 is in a closedconfiguration, upper surfaces 405 of the beads 304 contact jaw member120 to maintain a predetermined distance between jaw member 110 and jawmember 120. Further, when the end effector 100 is in a closedconfiguration, upper surfaces 405 of the beads 304 increase the overallgrasping strength of the jaw members 110 and 120 when grasping tissuetherebetween.

The first plate 301 may include indents 305 defined therein configuredto support the one or more beads 304. As described in more detail below,a lower surface 404 of the bead 304 is positioned in the indent 305 ofthe first plate 301 during an initial manufacturing step (see, e.g.,FIG. 3A).

Alternatively, the first plate 301 may include one or more openings 403defined therein (see, e.g., FIGS. 4A and 4B) that support the lowersurface 404 of the beads 304 atop the jaw support of jaw member 110.Thus, when the end effector 100 is in a closed state, the lower surface404 of the beads 304 directly contacts the support 116 of jaw member 110and the upper surface 405 of the beads 304 directly oppose jaw member120, thus maintaining desired spacing between jaw member 110 and jawmember 120 during sealing.

Referring back to FIGS. 3A-3C, the first plate 301 and the second plate302 form a substantially spherical shape around the beads 304. The shapeand size of the beads 304 may be substantially the same as a spaceformed between the first plate 301 and the second plate 302, thuscapturing the beads between the first plate 301 and the second plate302. Exemplary embodiments of the present disclosure are not limited tobeads having a spherical shape, and other shapes may be employed, asdesired. For example, the beads described herein may have a top-hat likeshape having a relatively wide first portion and a relatively narrowsecond portion disposed on the first portion.

The first plate 301 and the second plate 302 may be mechanically weldedtogether or there may be a mechanically interfacing element (not shown)between the first plate 301 in direct contact with the second plate 302(e.g., the first and second plates 301 and 302 may be separately formedstructures that are in direct contact with each other to capture themetallic glass bead 304 therebetween). The first plate 301 may be bondedwith or adhered to (e.g., by welding) the second plate 302 to capturethe beads 304 between the first plate 301 and the second plate 302. Asan example, the first plate 301 and the second plate 302 may each beformed on beads 304. The beads 304 may include a lower portion having afirst width and an upper portion have a second width smaller than thefirst width. The upper portion of the beads 304 may include a width thatis configured to project through the opening 303 defined in the secondplate 302.

The first plate 301 and the second plate 302 may be configured to stackon top of each other to allow for a force sensor and/or a temperaturesensor to be positioned between the plates. The force sensor allows anamount of force generated between the jaw members 110 and 120 to bemeasured at either of the first or second jaw members 110 or 120. Apressure sensor may also be positioned between the first and secondplates (e.g., between the first plate 301 and the second plate 302 whenstacked on each other). Descriptions of jaw members 110 and/or 120herein are similarly applicable to jaw member 520, a jaw member opposingjaw member 520 (not shown), jaw member 710 and jaw member 720 describedin more detail below.

The first plate 301 and the second plate 302 may be longer than thesupport 116 of jaw member 110 and/or jaw member 120 forming a distaloverhang 111 (see, e.g., FIG. 3C) at a distal end of the support (FIGS.3A, 3B and 3C). As a result thereof, one or more of the beads 304 may belocated distally of support 116 of jaw member 110 and/or jaw member 120.However, when the first plate 301 and the second plate 302 forming a twoplate construction are relatively narrow, a bead 304 is omitted distalof the support 116, as described in more detail below with reference toFIGS. 5A-7B. Further, the first plate 301 and the second plate 302 maybe stacked on each other to support the distal overhang 111, thuspreventing bending or warping of distal overhang 111. For example, thefirst plate 301 may maintain heat treated properties to increase theoverall strength of spacer 300 including the first plate 301 and thesecond plate 302. Alternatively, one or both jaw members, e.g., jawmember 110, may include a support 116 long enough to underlie overhang111 (e.g., support 116 is substantially the same length as the firstplate 301 and the second plate 302).

Referring to FIG. 3C, insulative overmold 118 is formed around support116 and extends to distal overhang 111. Insulative overmold 118 providesfurther structural support for distal overhang 111. As described in moredetail below with reference to FIGS. 5A-7B, a distal portion of anovermold layer (e.g., overmolds 118, 518 or 718) positioned distal of aproximal support structure (e.g., support 116) may form a distal spacermaintaining spacing between distal portions of first and second jawmembers including overhang 111.

Referring again to FIGS. 3A to 3C, a method of manufacturing anelectrosurgical instrument in accordance with aspects of the presentdisclosure includes positioning a first plate 301 including a pluralityof indents 305 on a first jaw member 110 of an end effector assembly100. The method includes positioning at least one bead 304 in an indentof the plurality of indents 305. The method includes positioning asecond plate 302 on the first plate 301 and on the at least one bead304. The second plate 302 includes at least one opening 303 definedtherein. The at least one opening 303 is configured to expose a surfaceof the bead 304 facing away from the first plate 301. The methodincludes attaching the first plate 301 to the second plate 302 tocapture the at least one bead 304 between the first plate 301 and thesecond plate 302.

Referring to FIGS. 5A, 5B, 6A and 6B, a series of alternate spacers 504are shown disposed along jaw member 520. An opposing jaw member (notshown) faces jaw member 520 and may have substantially the samestructure and configuration as jaw member 520. More particularly, jawmember 520 includes a plurality of capture tabs 509 disposed atop thesupport base 516 that extend at least partially along the lengththereof. Each spacer 504 is configured to seat between a series ofadjacent capture tabs 509 to capture and secure each spacer 504 atop jawsupport 516 (see, e.g., FIG. 5A). The capture tabs 509 may include edgetabs positioned along edges of the first or second jaw members 110 or120. Once secured (or at least seated) atop the jaw support 516, asealing plate 502 is secured atop the spacers 504 via an insulativehousing (overmold) 518 or other mechanical securement process. Sealingplate 502 may include a series of openings (not shown) defined thereinthat vertically align in registry with the spacers 504 to facilitateassembly (see, e.g., FIG. 5B).

As can be appreciated, variously-sized spacers 304, 504 may be utilizedalong or across the jaw support 116, 516 depending upon a particularpurpose. For example, spacers 304, 504 of different heights may bedisposed along the jaw support 116, 516 to create different gapdistances between jaw members 110, 120 when approximated. Likewise,different height spacers 304, 504 may be disposed across the jaw members110, 120 depending on a particular purpose. Spacers 304, 504 of a firstheight may be disposed at the proximal and distal ends of the jawsupport 116, 516 and spacers 304, 504 of a different height may bedisposed therebetween. Spacers 304, 504 of different widths or diametersmay also be configured along or across the jaw support 116, 516.

FIG. 6A illustrates a first base plate 601 and a second base plate 602on the first base plate 601. An attachment notch 603 formed by an insetsidewall 604 of the first base plate 601 (or alternatively, of thesecond base plate 602) is formed between the first and second baseplates 601 and 602. In FIG. 6A, overmold layer 518 is not illustrated inorder to illustrate the exposed attachment notch 603. In FIG. 6B, theovermold layer 518 is illustrated and is formed about the first attachednotch 603. The technical features described with reference to the firstand second plates 301 and 302 (see, e.g., FIGS. 3A to 4B) are similarlyavailable to the first and second base plates 601 and 602 whenevertechnically feasible.

Referring to FIGS. 6A and 6B, the overmold layer 518 is formed about thefirst jaw member 520 to secure the first and second base plates 601 and602 to the first jaw member 520. In particular, the overmold layer 518is formed in the attachment notch 603 to secure the first and secondbase plates 601 and 602 to the first jaw member 520. The first andsecond base plates 601 and 602 may be secured to each other, forexample, by mechanical welding together or any known method in the art.

The first and second base plates 601 and 602 may form a plurality ofattachment notches 603 intermittently spaced apart from each other alonga length of one or both lateral facing sides of the first jaw member520. Similar attachment notches 603 may be formed on a second jaw member(not shown) facing the first jaw member 520.

A spacer (see, e.g., spacers 304 and 504) may be captured between thefirst and second base plates 601 and 602, as described herein. Thespacer may be secured to the first jaw member 520.

Referring to FIGS. 6A to 6C, the first base plate 601 may include anopening aligned with an opening formed in the second base plate 602. Anovermold layer (e.g., the overmold layer 518 or an overmold layer 616)may extend through the openings formed in the first and second baseplates 601 and 602 (see, e.g., vertical arrows illustrated in FIG. 6C).The extended overmold layer may form spacers (see, e.g., spacers 304 and504) and/or may form the capture tabs 509 and/or may form mold-throughdots 704.

Referring to FIGS. 3A to 3C and 6A to 6C, a method of manufacturing anelectrosurgical instrument includes: positioning the first base plate601 including a plurality of indents (see, e.g., indents 305) on a firstjaw member 520 of an end effector assembly; positioning one or morespacers (e.g., spacer 304 or 504) in an indent of the plurality ofindents; positioning the second base plate 602 on the first base plate601 and on the one or more spacers, the second base plate 602 includingone or more openings (see, e.g., opening 303) defined therein thatexposes a surface of the spacer facing away from the first base plate601, and the second base plate 602 forming a laterally facing attachmentnotch 603 with the first base plate; forming the overmold layer 518about the first jaw member 520 in the laterally facing attachment notch603 to secure the first and second base plates 601 and 602 to the firstjaw member 520, which may be referred to herein as a lateral securingfeature.

Referring particularly to FIG. 6C, according to an exemplary embodimentof the present disclosure, the method includes forming a first overmoldlayer 616 about the first jaw member 520 to penetrate each of first andsecond openings of the first and second base plates 601 and 602, thefirst overmold layer 616 vertically securing the first and second baseplates 601 and 602 to the first jaw member 520, which may be referred toherein as a vertical securing feature, the first overmold layer 616 alsoforming spacers, capture tabs or mold-through dots, as described herein.The method also includes forming a second overmold layer 518 about, inpart, the first overmold layer 616 in the laterally facing attachmentnotches 603, the second overmold layer 518 laterally securing the firstand second base plates 601 and 602 to the first jaw member 520.

According to an exemplary embodiment of the present disclosure, a spacer(e.g., spacer 304 or 504) as described herein may be secured to thefirst jaw member 520 to secure the first and second base plates 601 and602 to the first jaw member 520. This may be referred to herein as aspacer securing feature.

Thus, as described herein, a first vertical securing feature, a secondlateral securing feature and/or a third spacer securing feature may beemployed to secure the first and second base plates 601 and 602 to thefirst jaw member 520.

Referring to FIGS. 7A and 7B, jaw members 710 and/or 720 includemold-through dots 704 disposed thereon. Jaw member 710 includes tipprotrusion 701. Jaw member 720 includes tip protrusion 702. Tipprotrusions 701 and 702 are positioned to contact each other when jawmembers 710 and 720 are in a closed configuration. As pressure isapplied to tip protrusions 701 and 702, jaw members 710 and 720 flextoward each other such that jaw members 710 and 720 contact themold-through dots 704 on the opposing jaw member to maintain a desireddistance between the jaw members 710 and 720. Alternatively, jaw members710 and 720 may be substantially parallel to each other such that anopposing jaw member 710 or 720 contacts the mold-through dots 704 on theopposite jaw member without jaw members 710 and 720 flexing toward eachother. The jaw members 710 and 720 each include a plurality of captureindents 709 forming a textured jaw surface. Each of the capture indents709 is recessed below the respective surfaces of one of the first orsecond jaw member 710 or 720. The mold-through dots 704 may be formed bygrowing overmold layers (e.g., 616 or 518) through openings formed inbase plates 601 and 602, similarly to how the capture tabs 509 may beformed (see, e.g., the vertical securing feature described above withreference to FIGS. 3A to 3C and 6A to 6C).

Referring to FIGS. 6A to 6C and 7A to 7B, a first overmold layer 718 isformed about the first jaw member 710. The first overmold layer 718forms a first tip protrusion 701 at a distal portion 714 of a first jawmember 710. The spacer (e.g., spacer 304 or 504) and the first tipprotrusion 701 maintain a substantially continuous distance between thefirst and second jaw members 710 and 720 in the closed position. Thefirst tip protrusion 701 may also be formed using overmold layers 616 or518.

A second overmold layer 719 is formed about the second jaw member 720.The second overmold layer 719 forms a second tip protrusion 702 at adistal portion 724 of the second jaw member 720. The second tipprotrusion 702 directly contacts the first tip protrusion 701 when thefirst and second jaw members 710 and 720 are in the closed position.

The spacer, in combination with the first tip protrusion 701, maintainsa substantially continuous distance between the first and second jawmembers 710 and 720 in the closed position. However, it is alsoanticipated that the first tip protrusion 701 alone, or the second tipprotrusion 702 alone, or the combination of the first and second tipprotrusions in the absence of the spacer, could maintain the distancebetween the first and second jaw members 710 and 720 in the closedposition, provided that a maximum threshold of force is not applied tothe first and second jaw members 710 and 720 to force the first andsecond jaw members 710 and 720 together.

Referring again to FIGS. 3A to 4 and 7A to 7B, the first and second baseplates (e.g., 301 and 302, or 601 and 602) may form an overhang 711extending distally from the first jaw member 710. The first overmoldlayer 718 is formed about the overhang 711 formed by the first andsecond base plates. The first overmold layer 718 provides support forthe overhang 711, such that the overhang 711 can maintain the distancebetween the first and second jaw members 710 and 720 in the closedposition.

The various embodiments disclosed herein may also be configured to workwith robotic surgical systems and what is commonly referred to as“Telesurgery.” Such systems employ various robotic elements to assistthe surgeon and allow remote operation (or partial remote operation) ofsurgical instrumentation. Various robotic arms, gears, cams, pulleys,electric and mechanical motors, etc. may be employed for this purposeand may be designed with a robotic surgical system to assist the surgeonduring the course of an operation or treatment. Such robotic systems mayinclude remotely steerable systems, automatically flexible surgicalsystems, remotely flexible surgical systems, remotely articulatingsurgical systems, wireless surgical systems, modular or selectivelyconfigurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consolesthat are next to the operating theater or located in a remote location.In this instance, one team of surgeons or nurses may prep the patientfor surgery and configure the robotic surgical system with one or moreof the instruments disclosed herein while another surgeon (or group ofsurgeons) remotely control the instruments via the robotic surgicalsystem. As can be appreciated, a highly skilled surgeon may performmultiple operations in multiple locations without leaving his/her remoteconsole which can be both economically advantageous and a benefit to thepatient or a series of patients.

The robotic arms of the surgical system are typically coupled to a pairof master handles by a controller. The handles can be moved by thesurgeon to produce a corresponding movement of the working ends of anytype of surgical instrument (e.g., end effectors, graspers, knifes,scissors, etc.) which may complement the use of one or more of theembodiments described herein. The movement of the master handles may bescaled so that the working ends have a corresponding movement that isdifferent, smaller or larger, than the movement performed by theoperating hands of the surgeon. The scale factor or gearing ratio may beadjustable so that the operator can control the resolution of theworking ends of the surgical instrument(s).

The master handles may include various sensors to provide feedback tothe surgeon relating to various tissue parameters or conditions, e.g.,tissue resistance due to manipulation, cutting or otherwise treating,pressure by the instrument onto the tissue, tissue temperature, tissueimpedance, etc. As can be appreciated, such sensors provide the surgeonwith enhanced tactile feedback simulating actual operating conditions.The master handles may also include a variety of different actuators fordelicate tissue manipulation or treatment further enhancing thesurgeon's ability to mimic actual operating conditions.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. While several embodiments of the disclosure have been shownin the drawings, it is not intended that the disclosure be limitedthereto, as it is intended that the disclosure be as broad in scope asthe art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

What is claimed is:
 1. An electrosurgical instrument, comprising: ahousing; an elongated shaft extending from the housing; an end effectordisposed at a distal portion of the elongated shaft and configured todeliver electrosurgical energy to tissue, the end effector including: afirst jaw member having a first electrode plate and a second jaw memberhaving a second electrode plate; a movable handle operably coupled tothe housing and configured to move at least one of the first or secondjaw members between an open position and a closed position; a first baseplate disposed on the first jaw member; a second base plate disposed onthe first base plate, the second base plate forming a series oflaterally facing attachment notches with the first base plate such thatthe first and second base plates cooperate to bound each of thelaterally facing attachment notches on at least four sides and each ofthe laterally facing attachment notches is unbounded along a laterallyfacing side of the first jaw member, the series of laterally facingattachment notches spaced apart from each other along the laterallyfacing side of the first jaw member; and an overmold layer formed aboutthe first jaw member, the overmold layer disposed within the series oflaterally facing attachment notches formed between the first and secondbase plates to secure the first and second base plates to the first jawmember.
 2. The electrosurgical instrument of claim 1, wherein the secondbase plate includes an opening defined therein, and wherein a spacer iscaptured between the first base plate and the second base plate, thespacer protruding through the opening defined in the second base plate.3. The electrosurgical instrument of claim 2, wherein the spacer iscoupled to the first jaw member.
 4. The electrosurgical instrument ofclaim 2, wherein the first base plate includes an opening aligned withthe opening of the second base plate, and wherein the overmold layerextends through the openings of the first and second base plates.
 5. Theelectrosurgical instrument of claim 2, wherein the spacer includes alower portion having a first width and an upper portion have a secondwidth smaller than the first width.
 6. The electrosurgical instrument ofclaim 2, wherein the spacer includes metal, ceramic or glass.
 7. Theelectrosurgical instrument of claim 1, wherein the end effector includesa knife configured to cut tissue disposed between the first and secondjaw members.
 8. The electrosurgical instrument of claim 1, furthercomprising an activation button extending from the housing and inregistration with the movable handle, wherein selective actuation of themovable handle controls the delivery of electrosurgical energy to thefirst and second jaw members.
 9. The electrosurgical instrument of claim1, wherein the first base plate and the second base plate aremechanically welded together.
 10. The electrosurgical instrument ofclaim 1, wherein the first and second base plates cooperate to boundeach of the laterally facing attachment notches on five sides.
 11. Anend effector for an electrosurgical instrument, comprising: a first jawmember having a first electrode plate and a second jaw member having asecond electrode plate; a first base plate disposed on the first jawmember; a second base plate disposed on the first base plate, the secondbase plate forming a series of laterally facing attachment notches withthe first base plate such that the first and second base platescooperate to bound each of the laterally facing attachment notches on atleast four sides and each of the laterally facing attachment notches isunbounded along a laterally facing side of the first jaw member, theseries of laterally facing attachment notches spaced apart from eachother along the laterally facing side of the first jaw member; and anovermold layer formed about the first jaw member, the overmold layerdisposed within the series of laterally facing attachment notches formedbetween the first and second base plates to secure the first and secondbase plates to the first jaw member.
 12. The end effector of claim 11,wherein the second base plate includes an opening defined therein, andwherein a spacer is captured between the first base plate and the secondbase plate, the spacer protruding through the opening defined in thesecond base plate.
 13. The end effector of claim 12, wherein the spaceris coupled to the first jaw member.
 14. The end effector of claim 12,wherein the first base plate includes an opening aligned with theopening of the second base plate, and wherein the overmold layer extendsthrough the openings of the first and second base plates.
 15. The endeffector of claim 12, wherein the spacer includes a lower portion havinga first width and an upper portion have a second width smaller than thefirst width.
 16. The end effector of claim 11, wherein the spacerincludes metal, ceramic or glass.
 17. The end effector of claim 11,further including a knife configured to cut tissue disposed between thefirst and second jaw members.
 18. The end effector of claim 11, whereinthe first and second jaw members are configured to receiveelectrosurgical energy.
 19. The end effector of claim 11, wherein thefirst base plate and the second base plate are mechanically weldedtogether.
 20. The end effector of claim 11, wherein the first and secondbase plates cooperate to bound each of the laterally facing attachmentnotches on five sides.